Art of increasing the cross-sectional area of metal rails or analogous articles.



No. 670,59l.

Patented Mar. 26, |901.

ANALUGOUS ARTICLES.

(Application filed Nay. 4, 1898A (No Model.)

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No. 670,59I. Patented Mar. 26, IQOI.

' G. S. MERRILL.

ART 0F INCREASING THE CROSS SECTIONAL AREA 0F METAL RAILS 0R ANALOGOUS ARTICLES.

(Application filed Nov. 4, 1898.) (No Model.) 5 She'eta-SheeI 2.

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n G. s. MERRILL.

ART 0F INCREASING THE CROSS SEGTIDNAL AREA 0F METAL RAILS 0R ANALOGOUS ARTICLES.

' (Application mea Nov. g1, 1 898 (No Modell)o 5 Sheets-Sheet 3.

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sis F nu. 670,591. Patented Mar. 26,191. G. s. MERRILL.

ART 0F INCREASING THE GROSS SECTIONAL AREA 0F METAL RAILS 0R ANALOGOUS ARTICLES. d

(No Modal.) (Application med Nov. 4, 1a98.\ 5 Sheets-Sheet 4l L4 16 A F1g.8. f l l 2 D M nl m3 l No. 670,59I. Patented Mar. 26,` |90l. G. S. MERRILL.

\ ART v0F INGBEASINGTHE CROSS `SECTIONAL AREA FVMETAL RAILS 0R ANALDGDUS ARTICLES.

(Application med mv.. 4, 189s.) A

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UNrrED STATES ATENT FFICE.

GEORGE SPENCER MERRILL, OF BELOIT, WISCONSIN, ASSIGNOR TO THE MERRILL PROCESS STEEL COMPANY, OF S'I. LOUIS, MISSOURI;

ART 0F INCREASING THE CROSS-SECTIONAL'AREA OF METAL RAILS 0R AIIALOGOUS ARTICLES.

SPEGIFCATION forming part of Letters Patent No. 670,591, dated March 26, 1901.

Application filed November 4, 1898. Serial No. 695,524. (No' model.)

To LZZ whom, it 10ft/,ty concern;

Be it known that I, GEORGE SPENCER MER- RILL, a citizen of the United States, residing at Beloit, in the county of Rock and State of Wisconsin, have made certain new and useful Improvements in the lArt of Increasing the Cross-Sectional Area of Metal Rails or Analogous Articles, of which the following is a specification.

My present process is an improvement in a branch of the process of restoring Worn rolled or drawn metallic articles described in the specification accompanying my application for Letters Patent of the United States serially numbered 668,512, and my apparatus is designed for use in carrying out my improved process.

In my improved process I increase the average cross-sectional area of rails treated in the following manner: I form in each rail a series of crimps, preferably after first heating the rail to a heat not lower than a red heat and not high enough to injure the metal therein; The crimps formed are preferably lateral crimps and are preferably all in the same plane and of about the same depth. I do not limit myself to any special form or depth of crimp, however, or the use of any special numberof crimps, but prefer a form and depth not calculated to strain or form cracks in the metal of the rail; and the crimping should shorten the rail sufficiently to give it a weight per foot of the distance in astraight line between its ends after crimping at least as great as the restored rail is intended to possess. After the crimping is completed I next, preferably While the rail is hot and preferably while it is not below a red heat, subject it to a pressure exerted substantially in the plane of its crimps and adapted to substantially straighten it, and at the same time I limit the longitudinal movement of the ends of the rail as well as its lateral movement and preferably also guide and limit the flow of the metal in the rail at angles to the plane of the crimps. In this way the greater part of the transverse pressure applied is converted into longitudinal pressure, and where the crimps are substantially uniform in size and are all inthe same plane all parts of the rail may, as a rule, be subjected by this process to longitudinal pressure simultaneously, or substanf tially so, and all difficulties relating to the nec# essary flow of the metal in the rail are overcome, and the rail is` substantially straight-4 ened and its cross-sectional area increased at the same time.

The outward movement of the ends of the crimped rail while being subjected to transcompressed rail are governed by the meansV guiding and limiting the transverse flow of the metal of which it is composed. The dey vice used for that purpose is ordinarily a suitable die.

After having its cross-sectional area increased the rail maybe subjected to a rolling or compression process of any kind for the purpose of reducing its cross-sectional area to any degree that is'desired; but this subsequent reduction of` cross-sectional area forms no necessary part of my present invention;

In the accom panying drawings I have shown an apparatus which is especially useful in carrying out my new process.

Referring to said drawings, Figure l is in part a side elevation and in part a vertical longitudinal section on line l l, FigsgS, 4, 5, and 7, with the supports for the crimpingrolls shown omitted. Fig. 2 is an enlarged vertical longitudinal section of details on line l1, Fig. 3. Fig. Risa rear end elevation of the press and discharger illustrated in Fig. l with supply-pipes, valve mechanism, and blocks F and F2 omitted. Fig. 4 is an enlarged vertical cross-section ot' the press 'bn line 4 4, Fig. l, looking forward. Fig. 5 is a detailed plan vview with the rear portion of the apparatus broken away and crimping mechanism omitted. Fig. 6 is an enlarged detailed vertical longitudinal section on line 6 6, Fig. 5. Fig. 7 is a detailed vertical transverse section on line 7 7, Fig. l. Fig. Sis an enlarged detailed vertical section on line l 1, Fig. 5, illustrating means IOO for feeding the press. Fig. 9 is a detailed horizontal cross-section of a guide on line 9 9, Fig. 1. Fig. 10 is au enlarged section of a valve on line 10 10, Fig. 5. Fig. 11 isasimilar View on line 11 11, Fig. 5. Fig. 12 is a detailed rear elevation with parts broken away. Fig. 13 is a vertical transverse section on line 13 13, Fig. S. Fig. 14 represents a side elevation of a worn rail, the side elevation of the same rail after crimping, and the approximate form of the rail after passing through my press. Fig. 15 is an enlarged cross-section of a compressed rail with the form of the rail before treatment shown in dotted lines. Fig. 16 is a detailed vertical longitudinal section on line 16 16, Fig. 5.

Similar letters refer to similar parts through out the several views.

The form of my apparatus shown in the drawings consists of rail-crimping mechanism, a rail-press, press feeding mechanism, shown arranged to cooperate with the crimping mechanism in doing the work of feeding, discharging mechanism, and withdrawing mechanism designed to cooperate with the discharger.

I prefer to use a vertical press, and in constructing the preferred form A thereof, Figs. 1,2, 3, 4, 5, and 8, I preferably use a top frame B and a bottom frame B', which are substantially alike, and preferably connect them together and hold them in position by means of f form one side of its head.

bolts C, provided with spacing-flanges c and c' and nuts c2. The bottom frame B' supports the lower member D, Figs. 1, 3, and 4, of a die. The member D is preferably secured to the press-frame B' by means of bolts d. Its face is preferably shaped so as to give the under side of rails passing through the press the desired form and size and preferably contains a groove d', adapted to form one side of the base of a rail, and a groove d2, adapted to From one side of the member D a part d2 projects upward, which is adapted to close one side of the diecavity D' when the die is closed. Above the member D of the die a vertically-reciprocat- `.ing member D2 is arranged, Whose face is like that of the member D and contains grooves cl' and cl2, arranged opposite the corresponding grooves in the lower member, and on the side opposite the one on which the part C72 of the member D projects it is provided with a downwardly projecting part d4, adapted to close its side of the die-cavity D. The member D2 of the die is preferably provided with flanges (L5, containing recesses d6, Fig. 1, and is shown secured to a platen E by means of bolts cl2, inserted laterally into the recesses (Z6 in the member D2 and recesses c above them in the sides of the platen.

To the sides of the platen E, Figs. 1, 3, 4, and 9, guideblocks E', each having a slot c formed in its face, are shown secured by bolts e2, and said platen preferably reciprocates between guide-plates F, filling said slots e' of the guide-blocks E', and shown fastened to the bolts C by means of strapsfand boltsf'. The upper member D2 of the die is guided by guide-blocks F', arranged below the plates F 011 their side of the press, and at points op posite the blocks F' similar blocks F2 are shown, arranged between the bolts Gand the lower member D of the die for the purpose of bracing the latter. The blocks F' and F2 are each secured to bolts C by means of an outside guideplate G and connecting-bolts g. The platen E is preferably operated by means of hydraulic power, and in the preferred form of my press I secure to the top of the platen, by means of bolts e2 or otherwise, two rams I-I, one of which reciprocates in a cylinderI and the other in a cylinder I', Figs. 1, 3, and 5. The cylinders I and I' are shown secured by means of bolts t' to the under side of the top frame B, and water is admitted to and escapes from said cylinders through ports J, coupled together by a pipe K, from which a pipe K' leads to the valve-port 7c3 of a valve* chest K2, Figs. 1, 5, and l1. The form of valvular devices illustrated forms no part of my invention. The valve-chest K2 shown contains in the valve-chamber 7c a slide-valve 702, governing the port 7c3, and an exhaust-port 7a4. A pipe 7c is shown leading from the latter, and the former is shown connected with the supply-main K3 by means of a pipe 707. The valve 7a2 is shown operated by means of a lever Khpivot-ally connected with the valverod 7o and connected with the valve-chest by means of a link 7010.

The platen E and the parts thereto attached are preferably raised by means of a pair of rams L, Figs. 1, 2, 3, and 5, preferably arranged above opposite ends of the platen E and each reciprocating in a vertical cylinder L', (shown secured to the top frame B by means of bolts Z. Water is admitted to and escapes from said cylinders through ports Z', and said ports Z are preferably at all times connected with the main supply-pipe K't3 by means of pipes Z2, Z3, and K7. The rams L are each shown provided with a T-head L3, containing a transverse bolt-hole Z4. To the head L3 a pair of hangers L4 are shown attached by a bolt Z5, passing through their upper ends and through said bolt-hole Z4. The lower ends of the hangers L" are shown sccured by means of bolts l to shoulders E2, projecting from opposite ends of the platen E.

The ends of the die-cavity D' are preferably closed by end gates M and M', Figs. 1, 2, 3, et, 5, and 8, preferably fastened together by means of apairof bolts M2, passing on opposite sides of the press. The inner faces f said gates rest against and may be guided by and heldin position longitudinally by the members D and D2 of the press-die and are preferably prevented from moving laterally by guide blocks M2, secured to the bolts M2, and which move in contact with the gude-plates G, Figs. 1 and 4, hereinafter referred to. Each of the gates M and M' preferably contains a central opening m, passing through it from top to IZO bottom, Figs. 1, 5, and 8, and the gate M, closing the mouth d2 of the die-cavity D', preferably has a cavity m formed in its inner face, Figs. 8 and ll, and a slot m2 in the under side thereof, Figs. 13 and 14. The gates M and M are raised by means of a pair of verticallymovable cylinders N, Figs. l, 2, 3, and 5, to which they are connected by hangers N. I prefer to use a pair of these hangers for each gate and preferably secure the upper ends of each pair to opposite sides of the proper cylinder by means of a bolt Tt and attach their lower ends to lugs m2, projecting from the gate, by means of bolts n. The cylinders N each reciprocate upon a stationary ram N2, secured to the top frame B by bolts n2, and which contains a passage TLS, connecting the interior of the cylinder N, reciprocating thereon, with a port n4. The ports 'n1 are preferably connected with a valve-chest N2, provided with passages, valves, and connections, substantially like the device for governing the passage of water to and from 'the cylin.

ders I and I illustrated in Fig. l1.

In the apparatus shown in the drawings the -crimping mechanism O, Figs. l and 7,'is preferably arranged in front of the press and in position to assist in feeding it. It preferably contains a pair of tinted crimping-rolls O', each having projections o, which enter the interdental spaces o' of the other, and each preferably contains an encircling groove 02, which preferably follows the contour of the roll and preserves substantially the same depth thronghout.- When the rollers are in position,said grooves come opposite and coact with each other. Each groove is perfectly adapt-ed to receive one side of a rail, and the opening 03, formed between the rolls by the two opposite'grooves, is preferably adapted to receive the end of a rail P when presented with one side uppermost. The rolls O are preferably journaled one above the other in standards O2 and may be provided with intermeshing gears O2, though they are not essential. A pulley Ol1 for communicating mo- `tion to the rolls is shown attached to one of them.' When the crimping-rolls O are in motion in the direction indicated by arrows in Fig. l, a rail presented to them on the outer side thereof, with one end in position to ent-er the opening o2 between them, is drawn in, crimped, and forced alongin the direction of the die-cavity of the press. After leaving the crimping-rolls the crimped rail P in the form of apparatus shown enters a guiding-trough O5, Figs. l, 5. and S, shown supported upon a standard o4,.and which preferably contains a slot 05, extending inward for a short distance from the inner end. rlhe crimping-rolls preferably continue to propel the railforward until its front end passes beyond said trough and preferably until it reaches a pair of vertical feed-rolls Q, which are preferably used and arranged in position to receive the crimped rail and pass it on to the press. Said rolls are preferably placed so that they can enter the vertical .opening m in the gate M when said gate is lowered and in that way avoid interference while standing nearer the mouth of the die-cavity than would otherwise be practicable. They are preferably supported upon shafts q and are preferably driven at a speed enabling them to cooperate with the crimpingrolls. Motion may be communicated to one of said shafts q from a Vshaft Q through gears g3 and g4 and from that shaft to the shaft q of the other roll through gears g5, Figs. l, 8, and l0, or by any other suitable means. After the crimped rail leaves the crimping-rolls and ceases to receive motion therefrom the feed-rolls Q continue to force it forward into the die-cavityD' until its outer end reaches a point where said rolls lose their grip, and it then becomes desirable to supply some additional means for forcing the rail completelyinto the die-cavity. In the mechanism which I prefer to use for that purpose a reciprocating .pusher-foot R is pivoted or hinged to a cross-head R, preferably by means of a substantially horizontal pivot T, and is preferably adapted to turn forwardl into a substantially horizontal position and to come to rest when turned back into a vertical position against a shoulder T. Said shoulder preferably contains a cavity T2, and at a point near the inner end of this cavity I preferably secure a tension-spring T3 to the cross-head and by securing the outer end of said spring to the back of the presser-foot R cause i t to tend at all times to draw said foot up against said shoulder T. Slides T4 preferably project from the ends of the cross-head R and slide in parallel grooves T5, formed in guides T6. Motion is communicated to the cross-head and the pusher-foot attached thereto through a piston-rod T7, attached to a piston T8, which reciprocates in a cylinder R2, having ports T9 and T10, and which is shown attached along the under side of the trough O5. The ports T9 and T10 are respectively connected by pipes T11 and T12 with ports T12 and T14 of a valve-chest R3, Figs. 5 and l0, whose inlet-portr16 is shown connected with the supply-main Kby a pipe los, and a pipe T17 leads from the exhaust-port T18. The valve-chamber T15 shown contains a common slide-valve T19, which in one position connects the pipe T11 with the exhaustand permits water to pass to the pipe T12 from the valve-chamber and in the opposite position connects the pipe T12 with the exhaust and allows water to pass from the valve-chanil'ier to the pipe T11. The valve T19 is shown operated by means ol' a lever R1, pivotally connectedavitn the valve-rod T20 and connected with the valve-chest by means of a -link T21. The described valve-chest R3 and its valve and ports are all of common form.

When water admitted to thevcylinder'R2 through the port T10, the piston T8 is forced back and draws the cross-head R' and-'presserfoot R back with it until the latter stands back of the rolls, as shown in dotted lines in Fig. 8. The rail to be subjected to the action IIO of the press is then started on its way through the crimping-rolls, and when it reaches the presser-foot presses it down in front of it and passes over it. As soon as the rail has passed the presser-foot water is admitted to the cylinder through the port T9 and allowed to eX- haust through the port T10 and the presserfoot R is forced forward and follows the rail until it strikes it and then pushes it forward into the die-cavity until the rail is in position to be operated upon by the press. The

presser-foot R preferably stops at the mouth of said cavity in the position in which it is illustrated in Figs. l, S, and 13 and preferably remains there, partially closing the mouth of said cavity, until the press has done its work. As soon as the rail is in position the end gates M and M of the press are lowered, so as to close the ends of the die-cavity D. When the gates M and M are lowered7 the presser-foot R passes into the cavity m' in the face of the gate M and preferably lits it closely. As soon as the end gates are closed the platen E is lowered, and the rail, Whose crimped form is approxi matelyin dotted lines in Fig. 1 and in full lines in Figs. 8 and 14, is substantially straightened and at the same time com pressed longitudinally and increased in cross-sectional area,while preferably at the same time kept in the shape of a rail in crosssection by the die. Its preferred form when compressed is indicated in Figs. l, 3, 14, and l5. .Vhen the remodeling of the rail is thus accomplished, the end gates and the platen E are both caused to rise bya suitable movement of the proper valve-levers, and the presser-foot R is then caused to resume its original position. I prefer to so proportion the parts as to cause the end gates to rise more rapidly than the platen E, so as to loosen the ends of the compressed rail, and, though it is not essential, I consider it a good plan to set the end gates in motion before the platen. In its upstroke the platen E preferably rises high enough to leave a longitudinal opening d5 in the side of the die-cavity for the passage of means for forcing the compressed rail P2 far enough forward to enable it to be gripped by suitable means for drawing it out of the press. In the form of discharger mechanism S, Figs. 3, 5, 6, and 16, which I prefer to use a cylinder S', provided with trunnions s and s', turns in a horizontal plane in bearings s2, shown supported bya standard s2. It contains a reciprocating piston s3, to which a piston-rod s4 is attached. The piston-rod s4 projects through the inner end of said cylinder, and the outer end of said rod is preferably provided with a finger S5, adapted to enter the opening Z5 in the side of the die-cavity when the platen E is at the end of its upstroke and said finger is in its outermost position, as shown in Fig. 3. The finger S5 is caused to extend forward far enough to enter said die-cavity by admitting water through a port s, back of the piston s3, and is drawn out of said cavity by admitting Water through far/0,591

the port 37 in front of said piston and allowing the water back of the piston to exhaust through the port S11.

To the ends of each of the trunnions s and S' tubes S8 and S9, whose outer' ends are respectively closed and which each contain perforations S10, are respectively preferably attached. The tube S8 is connected with the port s by means of a pipe S11, and the tube S9 is connected with the port 37 by means of a pipe 312. The tube 88 rotates in a pipe-coupling S13, which connects its perforations S10 with a pipe S14, and the tube s4 rotates in a similar coupling 313, which connects its perforations 310 with a pipe S15. rThe pipes S14 and S15 lead, respectively, to ports T13 and T14 of a Valve-chest S3, which, together with its interior mechanism, is preferably exactly like the Valve-chest R3, Fig. 10, and corresponding parts are lettered alike in each. The chest S8 is shown connected with the supply-main by pipes S111' and k1. In operating the discharger the piston s1 is forced out to the end of the stroke, so that its finger .S5 is directly behind the rear end of the rail, as shown in Figs. 3 and 5, and then while thus extended they are moved forward in the arc of a circle and made to force the compressed rail far enough out of the diecavity to enable the rotating withdrawingrolls T to catch it. After that water is admitted into the cylinder through the port S7 and the piston-rod retracted and its finger S5 drawn out of the opening through the side of said die. At the same time the cylinder S' and said piston-rod and linger are caused to swing back until the cylinder is once more in the position in which it is illustrated. This swinging motion is preferably communicated to the cylinder S by means which I will now describe. A cylinder S4, attached to and supported by the standard S2, contains a reciprocating piston-head S17, whose pistonrod S18 is provided at its outer end with a T- head S19, which is shown connected with trunnions S20, projecting from the cylinder` S by means of links 321. The cylinder S4 is provided with ports S22 and $23, from which pipes S24 and 825 lead to a valve-chest S5, which and the valve mechanism therein may be in all respects like those of the valve-chests R3 and S3. The pipe S24 preferably connects with a port T13 and the pipe 525 with a port T11. The withdrawing-rolls T, Figs. l and 12, are preferably in all respects like the rolls Q, hereinbefore described, and preferably rotate at about the same speed and in the same direction. They are preferably arranged immediately beneath the opening 'm in the gate M', as shown, and enter said opening when the gate is lowered. They are preferably supported upon shafts t, journaled in bearings 1 and t2. One of the shafts t in the arrangement illustrated receives motion from a shaft T' through gears t3 and 254, and from that shaft motion is communicated to the shaft tot' the other roll through gears t5 or any other suitable means. When the longitudinally-compressed IOO IIO

' rail l?2 is pushed far enough out of the die-cavity D' to be gripped by the rolls T, they catch it and continue its withdrawal until it is pulled completely out of the die-cavity. After it leaves said rolls it may be removed from their neighborhood by any suitable means.

Though the apparatus described is the one I prefer to use in carrying out my process,any other suitable apparatus may be used.

I do not herein claim an apparatus for carrying out my new process, the same constituting the subject-matter of an application (which is a division hereof) for'Letters Patent iiled August 3, 1900, Serial No. 25,753.

I claiml l. The process of increasing the cross-sectional area of metal rails and analogous articles consistingin formingin each article treated a series of crimps, and after crimping it, subjecting it to transverse pressure substantially in the plane of its crimps, While limiting its movement at an angle to the direction in which pressure is applied, and the longitudinal movement of its ends, and so transforming a part of the transverse pressure aping in each, a series ofcrimps in substantially the same plane; and subjecting each crimped rail or other article While at a temperature not lower than a red heat, to transverse pressure, substantially in the plane of its crimps, while limiting its movement at an angle to the plane of its cri inps, and the longitudinal movement of its ends and so transforming a part of the transverse pressure applied, int-o longitudinal pressure.

3. The process of increasing the cross-sectional area of metal rails and analogous artiticles, consisting in forming in each article treated, a series of lateral crimps in substantially the same plane, and subjecting each crimped article to transverse pressure substan tially in the plane of its crimps,while limiting its movement, at an angle to the plane of its crimps, and the longitudinal movement of its ends, and governing the transverse iiow of the metal therein, 'and so transforming a part of the transverse pressure applied into longitudinal pressure and increasing its cross-sectional area and giving it a substantially uniform size and shape in cross-section, throughout simultaneously, substantially as described.

GEORGE SPENCER MERRILL.

Witnesses:

' BENJ. F. REX,

STEPHEN WM. HIRsoHBEEG. 

